WO2019070034A1 - Three-dimensional laminate shaped article manufacturing device and three-dimensional laminate shaped article manufacturing method - Google Patents

Abstract

The three-dimensional laminated three-dimensional object manufacturing apparatus flaws the surface portion of a three-dimensional laminated three-dimensional object formed by curing the conductor powder and a beam irradiation unit that irradiates a beam to the conductor powder arranged in a layer. A nondestructive inspection unit and an energy control unit for controlling the energy of the beam. The energy control unit increases the energy of the beam when irradiating the beam to the repair area set according to the flaw detection result by the nondestructive inspection unit.

Description

Three-dimensional laminated object manufacturing apparatus and three-dimensional laminated object manufacturing method

The present disclosure relates to a three-dimensional laminated three-dimensional object manufacturing apparatus and a three-dimensional laminated three-dimensional object manufacturing method.

Conventionally, there is an apparatus for producing a three-dimensional product by arranging powder in the form of a layer on a work table, applying energy to selected portions of the powder layer and sequentially melting them (see, for example, Patent Document 1) . In an apparatus for producing such a three-dimensional product, one powder layer is partially melted, and after the molten powder hardens, another powder layer is formed thereon, and then a selected portion is melted. Curing is repeated to produce a three-dimensional product.

Japanese Patent Publication No. 2003-531034

Conventionally, defective three-dimensional products are not used as products but discarded as defective products. Patent Document 1 mentioned above does not describe how to handle a three-dimensional product having defects. An object of the present disclosure is to provide a three-dimensional laminated three-dimensional object manufacturing apparatus and a three-dimensional laminated three-dimensional object manufacturing method capable of detecting a defect in a surface layer portion and repairing the detected defect.

In the three-dimensional laminated three-dimensional object manufacturing apparatus of the present disclosure, a beam irradiation unit that irradiates a beam to the conductive powder arranged in a layer, and a surface layer portion of the three-dimensional laminated three-dimensional object formed by curing the conductive powder. And an energy control unit for controlling the energy of the beam. The energy control unit increases the energy of the beam when irradiating the beam to the repair area set according to the flaw detection result by the nondestructive inspection unit.

According to the present disclosure, it is possible to provide a three-dimensional laminated three-dimensional object manufacturing apparatus and a three-dimensional laminated three-dimensional object manufacturing method capable of detecting a defect in the surface layer and repairing the detected defect.

FIG. 1: is a block diagram which shows the three-dimensional laminated molded article manufacturing apparatus of one Embodiment. FIG. 2 is a cross-sectional view showing a three-dimensional laminate-molded article in which internal defects are detected. FIG. 3 is a block diagram of the three-dimensional layered object manufacturing apparatus shown in FIG. FIG. 4 is a view showing the arrangement of the inspection coil in the probe in FIG. 3 from above. FIG. 5 is a flowchart showing the procedure of the three-dimensional laminated three-dimensional object manufacturing method of one embodiment.

In the three-dimensional laminated three-dimensional object manufacturing apparatus of the present disclosure, a beam irradiation unit that irradiates a beam to the conductive powder arranged in a layer, and a surface layer portion of the three-dimensional laminated three-dimensional object formed by curing the conductive powder. And an energy control unit for controlling the energy of the beam. The energy control unit increases the energy of the beam when irradiating the beam to the repair area set according to the flaw detection result by the nondestructive inspection unit.

Since this three-dimensional laminated three-dimensional object manufacturing apparatus includes the nondestructive inspection unit, defects in the surface layer portion of the three-dimensional laminated three-dimensional object can be detected by the nondestructive inspection unit. Since the three-dimensional laminate model manufacturing apparatus includes the energy control unit, it is possible to increase the energy of the beam when irradiating the beam to the repair area including the defect detected by the nondestructive inspection unit. Thereby, the three-dimensional laminated three-dimensional object manufacturing apparatus can apply energy of the beam to defects existing in the lower layer while irradiating the beam to the next layer of the conductor powder. The three-dimensional laminate model manufacturing apparatus can repair a defect.

The beam irradiation unit includes an electron gun for irradiating an electron beam as a beam, an acceleration power supply for supplying an acceleration voltage to the electron gun, and a coil unit for forming a magnetic field in a region in front of the irradiation port of the electron gun. It is also good. The energy control unit may include an acceleration voltage control unit that controls an acceleration voltage and a coil control unit that controls a coil unit. Thereby, by irradiating an electron beam with respect to conductor powder from an electron gun, conductor powder can be fuse | melted and it can be hardened and a three-dimensional laminate-molded article can be manufactured. The acceleration voltage control unit can increase the acceleration voltage when irradiating the repair area with the electron beam. As a result, the energy of the electron beam can be increased, and the electron beam can be applied to the defect existing in the lower layer while irradiating the layer of the conductor powder of the next time with the electron beam. As a result, the three-dimensional laminate model manufacturing apparatus can melt and repair the defect.

The coil control unit may lower the scanning speed of the electron beam when irradiating the repair region with the electron beam. This makes it possible to increase the energy applied to the region irradiated with the electron beam, so that while irradiating the layer of the conductor powder next time with the electron beam, the energy of the beam with respect to the defect existing in the layer thereunder Can be granted. The three-dimensional laminate model manufacturing apparatus can melt and repair defects.

In the three-dimensional laminated three-dimensional object manufacturing method of the present disclosure, a beam is irradiated to a conductor powder arranged in a layer to melt and cure the conductor powder, thereby manufacturing a three-dimensional laminated three-dimensional object A method of manufacturing the object, wherein the conductor powder of the first layer held in the holder is irradiated with a beam to melt the conductor powder of the first layer, and the conductor powder of the first layer is melted By a nondestructive inspection process for flaw detection of the surface layer portion of the three-dimensional laminate after being cured and cured, a lamination process for laminating the conductor powder of the second layer on the three-dimensional laminate, and a nondestructive inspection process And d) repairing the area set in accordance with the flaw detection result. In the repair step, when the beam is irradiated to the conductive powder of the second layer, the energy of the beam is increased to repair the area.

In this three-dimensional layered manufacturing method, defects in the surface layer portion of the three-dimensional layered object can be detected by performing the nondestructive inspection process. In the repair step of this three-dimensional layered object manufacturing method, when irradiating the beam to the conductor powder of the second layer laminated on the three dimensional layered object, the energy by the beam can be increased, The area containing the detected defect can be repaired. Thereby, the conductor powder of the second layer can be melted while repairing the defects contained in the first layer to produce a three-dimensional laminated three-dimensional object.

Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the drawings. In the drawings, the same parts or corresponding parts are denoted by the same reference numerals, and redundant description will be omitted.

A three-dimensional laminated three-dimensional object manufacturing apparatus (hereinafter referred to as "manufacturing apparatus") 1 shown in FIG. 1 is a so-called 3D printer, which applies energy partially to metal powder (conductor powder) 2 arranged in layers. , Metal powder 2 can be melted or sintered. The manufacturing apparatus 1 repeats melting or sintering a plurality of times to manufacture a three-dimensional component (three-dimensional laminate-molded product) 3. The three-dimensional component 3 is, for example, a machine component or the like, and may be another structure. Examples of the metal powder include titanium-based metal powder, Inconel (registered trademark) powder, and aluminum powder. The conductor powder is not limited to a metal powder, and may be, for example, a powder containing carbon fibers and a resin, such as CFRP (Carbon Fiber Reinforced Plastics), or a powder having another conductivity.

The manufacturing apparatus 1 includes a vacuum chamber 4, a work table (holding unit) 5, an elevating device 6, a powder supply device 7, an electron beam irradiation device (beam irradiation unit) 8, a nondestructive inspection device 9 and a controller 31. The vacuum chamber 4 is a container in which the inside is in a vacuum (low pressure) state, and a vacuum pump (not shown) is connected. The work table 5 shown in FIG. 2 has, for example, a plate-like shape, and is a holding portion on which the metal powder 2 which is a raw material of the three-dimensional component 3 is disposed. The metal powder 2 on the work table 5 is arranged, for example, in multiple layers in layers. The work table 5 has, for example, a rectangular shape in a plan view. The shape of the work table 5 is not limited to a rectangle, and may be a circle or another shape. The work table 5 is disposed in the vacuum chamber 4, for example, in a recess that is recessed downward at the bottom. The work table 5 is movable in the Z direction (vertical direction), and descends sequentially according to the number of layers of the metal powder 2. A guide unit 10 for guiding the movement of the work table 5 is provided on the outer periphery of the work table 5. The guide portion 10 has a rectangular cylindrical shape (a cylindrical shape when the work table is circular) so as to correspond to the outer shape of the work table 5. The guide portion 10 and the work table 5 form an accommodating portion for accommodating the metal powder 2 and the three-dimensional part 3 shaped. The work table 5 is movable in the Z direction inside the guide portion 10. For example, the guide unit 10 constitutes a part of the vacuum chamber 4.

The lifting device 6 raises and lowers the work table 5. The lifting device 6 includes, for example, a rack and pinion type drive mechanism, and moves the work table 5 in the Z direction. The lifting device 6 includes a rod-like vertical member (rack) connected to the bottom surface of the work table 5 and extending downward, and a drive source for driving the vertical member. As a drive source, for example, an electric motor can be used. A pinion is provided on the output shaft of the electric motor, and a side surface of the vertical member is provided with a tooth profile that meshes with the pinion. The electric motor is driven, the pinion rotates, power is transmitted, and the vertical direction member moves in the vertical direction. By stopping the rotation of the electric motor, the vertical member is positioned, the position of the work table 5 in the Z direction is determined, and the position is held. The vertical position adjustment mechanism is not limited to the rack and pinion type drive mechanism. The vertical position adjustment mechanism may include, for example, another drive mechanism such as a ball screw or a cylinder.

The powder supply device 7 shown in FIG. 1 includes a raw material tank 11 which is a storage section for storing the metal powder 2 and a powder application mechanism 12 for leveling the metal powder 2. The raw material tank 11 and the powder coating mechanism 12 are disposed in the vacuum chamber 4. The raw material tank 11 is disposed above the work table 5 in the Z direction. The raw material tanks 11 are disposed, for example, on both sides of the work table 5 in the Y direction intersecting the Z direction. Below the raw material tank 11, an overhang plate 13 is provided. The overhang plate 13 extends laterally from the upper end of the guide portion 10. The overhang plate 13 forms a plane intersecting the Z direction around the work table 5. The metal powder 2 stored in the raw material tank 11 flows out from the raw material tank 11 and deposits on the overhang plate 13.

The powder application mechanism 12 is movable in the Y direction above the work table 5 and the overhang plate 13. The powder coating mechanism 12 scrapes the metal powder 2 deposited on the overhang plate 13 onto the work table 5 and smooths the surface (upper surface) 2 a of the top layer of the laminate of the metal powder 2 on the work table 5. . The lower end portion of the powder application mechanism 12 abuts on the surface 2 a of the laminate of the metal powder 2 to make the height uniform. The powder coating mechanism 12 has, for example, a plate shape, and has a predetermined width in the X direction. The X direction is a direction intersecting the Z direction and the Y direction. The length in the X direction of the powder coating mechanism 12 corresponds, for example, to the total length in the X direction of the work table 5. The manufacturing apparatus 1 may be configured to include a roller unit, a rod-like member, a brush unit, and the like instead of the powder application mechanism 12.

The electron beam irradiation device 8 includes an electron gun 14, an acceleration power supply 15, and a coil unit 16. The electron gun 14 includes a cathode 14a, an anode 14b and a filament 14c. The cathode 14 a, the anode 14 b and the filament 14 c are electrically connected to an accelerating power supply 15. The negative electrode of the acceleration power supply 15 is grounded. The acceleration voltage is, for example, -60 kv. The acceleration voltage is a potential difference between the cathode 14a and the anode 14b. The cathode 14a is heated by the filament 14c. Electrons are emitted from the heated cathode 14a. Electrons are accelerated according to the potential difference between the cathode 14a and the anode 14b. The electron beam (electron beam) B is irradiated into the vacuum chamber 4 through the irradiation port 14 d of the electron gun 14.

The coil portion 16 forms a magnetic field in the front region of the irradiation port 14 d of the electron gun 14. The front area is a front area in the irradiation direction of the electron beam B. The coil unit 16 includes an aberration coil 17, a focus coil 18, and a deflection coil 19. The aberration coil 17, the focus coil 18 and the deflection coil 19 are arranged in this order from the side of the electron gun 14 in the irradiation direction of the electron beam B, for example. The aberration coil 17 is disposed around the electron beam B emitted from the electron gun 14 and focuses the electron beam B. The focus coil 18 is disposed around the electron beam B emitted from the electron gun 14 and corrects the deviation of the focus position of the electron beam B. The deflection coil 19 is disposed around the electron beam B emitted from the electron gun 14 and adjusts the irradiation position of the electron beam B. The deflection coil 19 performs electromagnetic beam deflection, so that the scanning speed at the time of irradiation of the electron beam B can be increased as compared with mechanical beam deflection. The electron gun 14 and the coil section 16 are disposed at the top of the vacuum chamber 4. The electron beam B emitted from the electron gun 14 is converged by the coil unit 16 to correct the focal position. The scanning speed of the electron beam B is controlled to reach the irradiation position of the metal powder 2.

The nondestructive inspection device 9 shown in FIG. 2 includes a probe (nondestructive inspection unit) 9a that flaws the surface layer portion 3a of the three-dimensional component 3. The probe 9 a is attached to the powder application mechanism 12. The probe 9 a is movable in the Y direction together with the powder coating mechanism 12. The probe 9 a may be movable separately from the powder application mechanism 12. The bottom surface of the probe 9 a is disposed above the lower end of the powder application mechanism 12. A gap is formed between the bottom of the probe 9 a and the surface 2 a of the laminate of the metal powder 2. The probe 9 a is not in contact with the metal powder 2 and the three-dimensional component 3. The probe 9a extends in the X direction intersecting the Y direction which is the scanning direction of the probe 9a. The probe 9a includes a plurality of inspection coils 20 arranged side by side in the X direction, as shown in FIG. The probe 9a includes a row of a plurality of inspection coils 20 aligned in the X direction. The plurality of rows of inspection coils 20 are arranged side by side in the Y direction. The inspection coil 20 of the probe 9a is housed, for example, in a box-shaped housing. In the illustrated example, the probe 9 a is disposed on the front side in the moving direction of the powder coating mechanism 12. The probe 9 a may be disposed on the rear side in the moving direction of the powder coating mechanism 12. After leveling the metal powder 2 by the powder coating mechanism 12, the probe 9 a may be flawed while passing over the metal powder 2.

The inspection coil 20 shown in FIG. 4 includes an excitation coil 21 and a pair of detection coils 22. The exciting coil 21 is supplied with an alternating current to generate a magnetic field. Thereby, the exciting coil 21 can generate an eddy current in the surface layer portion 3 a of the three-dimensional component 3. The exciting coil 21 is formed, for example, around an axis extending in the Z direction. The pair of detection coils 22 is disposed inside the excitation coil 21. The detection coil 22 is formed, for example, around an axis extending in the Z direction. A ferrite core (iron core) is disposed inside the detection coil 22. The ferrite core has, for example, a rod-like shape and extends in the Z direction. The ferrite core may be cylindrical or prismatic. The pair of detection coils 22 detect a change in the magnetic field due to the eddy current of the surface layer portion 3a. The surface layer portion 3a may include the surface of the three-dimensional component 3 and an internal portion near the surface. The surface layer portion 3a may include, for example, a region from the surface to a depth of 1 mm. The surface layer portion 3a may include, for example, a region up to a depth of 2 mm, or may include regions up to another depth. The probe 9a can be simultaneously subjected to flaw detection to a depth of a plurality of layers (for example, five layers) of the metal powder 2 as the surface layer portion 3a of the three-dimensional component 3.

When there is a defect C in the surface layer portion 3a, the flow of the eddy current is changed, which changes the magnetic field. By detecting the change of the magnetic field by the detection coil 22, the presence or absence of the defect C can be detected. One of the pair of detection coils 22 may detect a change in the magnetic field, and the other may not detect the change in the magnetic field. In such a case, the change in the magnetic field can be accurately detected by calculating the difference between the signals detected by the pair of detection coils 22. By calculating the difference between the signals detected by the plurality of detection coils 22 in this manner, the difference between the signals becomes the largest when the probe 9a passes over the defect C. Therefore, the electrical noise can be suppressed and the defect C can be detected accurately. The defects C detected by the detection coil 22 include, for example, poor penetration, cracking, fusion, porosity, and the like.

The controller 31 shown in FIGS. 1 and 3 is a control unit that controls the entire apparatus of the manufacturing apparatus 1. The controller 31 is a computer configured from hardware such as a central processing unit (CPU), read only memory (ROM), and random access memory (RAM) and software such as a program stored in the ROM. The controller 31 includes an input signal circuit, an output signal circuit, a power supply circuit, and the like. The controller 31 includes an arithmetic unit 32, an acceleration voltage control unit (energy control unit) 33, a coil control unit (energy control unit) 34, and a storage unit 35. The controller 31 is electrically connected to the acceleration power supply 15, the aberration coil 17, the focus coil 18, the deflection coil 19, the powder coating mechanism 12, the probe 9 a, the elevating device 6, the display unit 41 and the operation unit 42.

The manufacturing apparatus 1 includes an energy control unit that controls the energy of the electron beam B. The controller 31 may include an acceleration voltage control unit 33 and a coil control unit 34 as an energy control unit.

The operation unit 32 performs an operation on the signal detected by the probe 9a. The calculation unit 32 can calculate, for example, the difference between the signals detected by the pair of detection coils 22. The calculation unit 32 can calculate, for example, the presence or absence of the defect C, the position of the defect C (the position in the X direction, the position in the Y direction), and the depth of the defect C (the position in the Z direction). The calculation unit 32 outputs the calculated inspection result (testing result) to the display unit 41. The calculation unit 32 stores the calculated inspection result in the storage unit 35.

The acceleration voltage control unit 33 controls the acceleration voltage applied by the acceleration power supply 15. The acceleration voltage control unit 33 increases the acceleration voltage more than usual depending on the position and depth of the detected defect C. The normal acceleration voltage is an acceleration voltage when there is no need to repair the defect C. The acceleration voltage at the normal time is, for example, an acceleration voltage required to irradiate the electron beam B capable of melting one layer of metal powder 2. The acceleration voltage control unit 33 increases the acceleration voltage to increase the velocity of electrons by the electron beam B. When melting the metal powder 2 deposited on the three-dimensional component 3, the acceleration voltage control unit 33 performs control to increase the acceleration voltage in accordance with the timing when the electron beam B is irradiated to the defect C. When the electron beam B is irradiated to a position away from the defect C after increasing the acceleration voltage, the acceleration voltage control unit 33 performs control to lower the acceleration voltage and return it to the normal value.

The coil control unit 34 controls the aberration coil 17 to converge the electron beam B. The coil control unit 34 controls the focus coil 18 to control the focus position of the electron beam B. The coil control unit 34 controls the deflection coil 19 to control the irradiation position of the electron beam B. For example, since the behavior of the electron beam B changes when the acceleration voltage is increased as compared with that in the normal state, the coil control unit 34 controls the amount of control in the aberration coil 17, the amount of control in the focus coil 18, the deflection coil 19 Can be corrected. For example, data on the control amount of the aberration coil 17, the control amount of the focus coil 18, and the control amount of the deflection coil 19 are stored in the storage unit 35.

The display unit 41 is, for example, a liquid crystal display device, and can display an inspection result and the like output from the controller 31. The display unit 41 displays, for example, information on the position, depth, and the like of the detected defect C. The display unit 41 can display information on the electron beam B emitted from the electron gun 14. The display unit 41 can display data on the acceleration voltage, the control amount of the aberration coil 17, the control amount of the focus coil 18, and the control amount of the deflection coil 19. The operation unit 42 is an input unit that can be operated by the user. The user can confirm the information displayed on the display unit 41 and change various settings (control amounts).

Next, a method of manufacturing a three-dimensional part (a method of manufacturing a three-dimensional laminated object) will be described. FIG. 5 is a flowchart showing the procedure of a method of manufacturing a three-dimensional part. The method of manufacturing a three-dimensional part is performed using, for example, the manufacturing apparatus 1.

First, in the manufacturing apparatus 1, the metal powder 2 is discharged from the raw material tank 11, the metal powder 2 of the first layer is supplied onto the work table 5, and the powder coating mechanism 12 is moved in the Y direction. The surface 2a of the laminate is leveled (step S1). Next, an irradiation step of irradiating the metal powder 2 on the work table 5 with the electron beam B is performed (melting step: step S2). In this irradiation step, the acceleration voltage control unit 33 controls the acceleration power supply 15 to control the acceleration voltage. As a result, the electrons are accelerated and the electron beam B is emitted from the electron gun 14. In the irradiation step, the coil control unit 34 controls the aberration coil 17 to focus the electron beam B, controls the focus coil 18 to control the focus position of the electron beam B, and controls the deflection coil 19 to control the electron beam. The irradiation position of B is controlled, and the scanning speed of the electron beam B is controlled.

Next, the controller 31 sends a command signal to the lifting device 6 to lower the work table 5 (step S3). Thereby, the space for laminating the metal powder 2 of the second layer on the first layer is secured.

After the metal powder 2 of the first layer (the nth layer) which has melted is cured, in the manufacturing apparatus 1, the metal powder 2 of the second layer (the n + 1th layer) is placed on the work table 5 (the metal powder 2 of the nth layer) (Layering process), the powder coating mechanism 12 is moved in the Y direction, and the surface 2a of the metal powder 2 of the second layer is leveled (step S4). At this time, when moving the powder application mechanism 12, a flaw detection process (nondestructive inspection process; step S5) is performed. For example, the surface 2a of the metal powder 2 of the second layer (the (n + 1) th layer) is leveled, and a flaw detection process is performed on the surface layer portion 3a of the first layer (the nth layer).

In the flaw detection process, an excitation process and a detection process are performed. In the exciting step, current is supplied to the exciting coil 21 to generate a magnetic field, thereby generating an eddy current in the surface layer portion 3a. In the detection step, the change of the magnetic field in the surface layer 3a is detected. For example, if there is a defect C, a shape discontinuity or the like in the surface layer portion 3a, the eddy current detours to change and the magnetic field changes. In the detection step, the calculation unit 32 calculates the difference between the signals detected by the pair of detection coils 22. The operation unit 32 generates image information indicating the inspection result based on the calculated result. The image information indicating the inspection result is output to the display unit 41 and displayed. The display unit 41 may display the position, the size, the direction, and the like of the defect C as image information indicating the inspection result.

Next, operation unit 32 determines the presence or absence of defect C based on the inspection result (step S6). Here, the calculation unit 32 may determine the presence or absence of the defect C based on the difference between the signals from the pair of detection coils 22. The user looks at the image information displayed on the display unit 41 and the defect C is detected. The presence or absence may be determined. If the defect C is not detected, the process proceeds to step S8. If the defect C is detected, the process proceeds to step S7.

In step S7, a repair preparation process is performed. In the repair preparation process, the controller 31 performs various settings for repairing the defect C. In the repair preparation process, the controller 31 sets, for example, a repair area including the defect C. In the repair preparation step, the controller 31 sets the control amount of the acceleration power supply when the electron beam B is irradiated to the repair area including the defect C. The controller 31 sets, for example, the control amount of the acceleration power supply 15 so as to increase the acceleration voltage. In the repair preparation process, the controller 31 sets the control amount of the coil unit 16 when the acceleration voltage is increased. The controller 31 can set, for example, the control amount of the aberration coil 17, the control amount of the focus coil 18, and the control amount of the deflection coil 19 in accordance with the increase amount of the velocity of electrons in the electron beam B. In the repair preparation step, the above control amount is set based on the position, size, and shape of the defect C, the control amount of the electron beam B in the past, and the like. These control amounts may be set by the user or may be set by the calculation unit 32 performing calculations. The set control amount is stored in the storage unit 35. The repair area including the defect C may be the defect C alone, may include the area around the defect C, or may include only a part of the defect C.

After the repair preparation process of step S7 is performed, the process returns to step S2. In this step S2 irradiation process, the electron beam irradiation apparatus 8 irradiates the electron beam B to the metal powder 2 of the second layer stacked on the first layer. In step S2, when the electron beam B is irradiated to the repair area including the defect C, control based on the control amount set in the repair preparation process is executed, and the acceleration voltage is increased. Control is performed. As a result, the energy of the electron beam B is increased, the electron beam B reaches the defect C, and the defect C is melted. Thereby, the repair process which repairs the defect C is implemented. In the irradiation step, when the electron beam B was irradiated to the metal powder 2 of the second layer in the region other than the repair region, the electron powder B was irradiated to the metal powder 2 of the previous first layer. The electron beam B is irradiated as well as time. That is, when the irradiation position of the electron beam B moves and deviates from the repair position including the defect C, the acceleration voltage control unit 33 returns the acceleration voltage.

After the irradiation process in step S2 is performed, steps S3 to S6 are repeated. If it is determined in step S6 that there is no defect, the process proceeds to step S8. In step S8, the controller 31 determines whether or not the formation is completed for all the layers of the three-dimensional part 3 and the part is completed. For example, it is determined whether or not modeling has been completed for the designed layer. If shaping of the three-dimensional part is not completed, the process returns to step S2. In this step S2, the electron beam irradiation apparatus 8 irradiates the electron beam B to the metal powder 2 formed in the previous step S4 to partially apply energy to perform melting. Hereinafter, the manufacturing apparatus 1 repeats the same process, performs modeling on all the layers of the three-dimensional part 3, and completes the manufacture of the three-dimensional part 3.

In the manufacturing apparatus 1 of the present embodiment, since the nondestructive inspection device 9 is provided, the defect C of the surface layer portion 3 a of the three-dimensional component 3 can be detected by the nondestructive inspection device 9. Since the manufacturing apparatus 1 includes the accelerating voltage control unit 33, when irradiating the electron beam B to the repair area including the defect C detected by the nondestructive inspection apparatus 9, the energy by the electron beam B is increased. Can. Thereby, the manufacturing apparatus 1 can apply the energy of the electron beam B to the defect C existing in the first layer under the second layer while irradiating the metal powder 2 of the second layer with the electron beam B. As a result, the defect C can be repaired.

The present disclosure is not limited to the embodiments described above, and various modifications can be made as described below without departing from the scope of the present invention. In the above embodiment, the energy of the electron beam B is increased by performing control of increasing the acceleration voltage, but the control of increasing energy of the beam is not limited to this. For example, the controller 31 may reduce the moving speed of the irradiation position of the electron beam B by decreasing the scanning speed of the electron beam B, and may increase the energy applied to the conductor powder. That is, when the coil control unit 34 irradiates the repair area with the electron beam B, the coil control unit 34 may perform control to make the scanning speed of the electron beam B lower than usual. The coil control unit 34 may simultaneously perform control to increase the acceleration voltage and control to decrease the scanning speed. That is, the scanning speed may be decreased while increasing the acceleration voltage. In the above embodiment, when the defect C is detected, the manufacturing apparatus 1 can also repair the defect C by irradiating the repair area including the defect C with the electron beam B again.

In the above embodiment, the electron beam B is irradiated to melt the conductor powder, but the beam irradiated to the conductor powder is not limited to the electron beam, and may be another energy beam. The three-dimensional laminated three-dimensional object manufacturing apparatus may include, for example, a laser transmitter and may be irradiated with a laser beam to melt the conductor powder. As described above, in the case of irradiating a laser beam, the coil control unit may perform control to increase the output of the laser beam, or may control to decrease the scanning speed of the laser beam. Thereby, when the beam is irradiated to the repair area, the energy by the beam can be increased to repair the defect.

In the above embodiment, as the nondestructive inspection unit for flaw detection of the surface layer portion 3a of the three-dimensional component 3, a case where eddy current is generated in the three-dimensional component 3 to perform flaw detection (eddy current flaw detection test) is described. The nondestructive inspection part is not limited to the one that conducts the eddy current flaw detection test. The nondestructive inspection unit may perform other nondestructive inspection such as, for example, a radiation transmission test. The nondestructive inspection unit may include a camera (imaging unit), and may set a repair area by detecting a defect based on the imaged image.

In the above embodiment, the powder application mechanism is moved in the Y direction to level the surface 2a of the powder laminate (powder layer), but the powder application mechanism is moved in the other directions in the XY plane. The surface 2a of the powder layer may be leveled. The manufacturing apparatus may move the powder application mechanism in the circumferential direction. The manufacturing apparatus may move the modeling tank including the work table relative to the powder coating mechanism in plan view to level the surface 2a. The shaping tank (guide portion) may be configured to reciprocate in, for example, the X direction, or may be configured to be movable in other directions. The modeling tank may be configured to be rotationally movable about an imaginary line extending in the Z direction. For example, the manufacturing apparatus includes a circular holding unit (working table) in plan view, and rotates the holding unit and the powder layer around an imaginary line (central portion of the holding unit) extending in the Z direction. Alternatively, the application and the beam irradiation may be sequentially performed.

1 Manufacturing device (three-dimensional laminated object manufacturing device)
2 Metal powder (conductor powder)
3 Three-dimensional parts (three-dimensional laminated object)
3a surface part 5 work table (holding part)
8 Electron Beam Irradiator (Beam Irradiator)
9 Nondestructive inspection device (nondestructive inspection part)
9a Probe 14 Electron gun 15 Acceleration power supply 16 Coil unit 33 Acceleration voltage control unit (energy control unit)
34 Coil control unit (energy control unit)
B Electron beam (electron beam)
C defect

Claims (5)

A beam irradiation unit which irradiates a beam to the conductor powder arranged in a layer;
A nondestructive inspection unit for detecting a surface layer portion of a three-dimensional laminated object formed by curing the conductive powder;
An energy control unit for controlling the energy of the beam;
The said energy control part is a three-dimensional laminated molded article manufacturing apparatus which increases the energy by the said beam, when irradiating a beam to the repair area | region set according to the flaw detection result by the said nondestructive inspection part. The beam irradiation unit
An electron gun for irradiating an electron beam which is the beam;
An acceleration power supply for supplying an acceleration voltage to the electron gun;
A coil unit for forming a magnetic field in a region in front of the irradiation port of the electron gun;
The energy control unit
An acceleration voltage control unit that controls the acceleration voltage;
The coil control part which controls the said coil part, The three-dimensional laminated molded article manufacturing apparatus of Claim 1 characterized by the above-mentioned. The three-dimensional stacked object manufacturing apparatus according to claim 2, wherein the acceleration voltage control unit increases the acceleration voltage when irradiating the electron beam to the repair area. The three-dimensional laminate model manufacturing apparatus according to claim 2 or 3, wherein the coil control unit reduces the scanning speed of the electron beam when irradiating the electron beam to the repair area. It is a three-dimensional laminated three-dimensional object manufacturing method which irradiates a beam to the conductor powder arranged in a layer, melts and hardens the said conductor powder, and manufactures a three-dimensional laminated three-dimensional object,
A step of irradiating the conductive powder of the first layer held by the holding portion with the beam to melt the conductive powder of the first layer;
A nondestructive inspection step of flawless surface layer portions of the three-dimensional laminate formed article after the conductor powder of the first layer is melted and cured;
Laminating the conductor powder of the second layer on the three-dimensional laminate;
And a repair process for repairing an area set according to the flaw detection result by the nondestructive inspection process.
In the said repair process, when irradiating the said beam to the said conductor powder of the said 2nd layer, the energy by the said beam is made to increase and the three-dimensional laminated molded article manufacturing method which repairs the said area | region.

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